Simulation of Robotic Friction Stir Welding of Aerospace Components

Friction stir welding (FSW) is an emerging manufacturing technology for aerospace structures. It will see widespread use in the future as it offers ways of creating lighter structures at lower manufacturing cost than traditional methods (riveting, adhesive bonding). Since its invention in 1991, FSW has known fast improvements and many studies have demonstrated its capability for joining a wide range of materials [1]-[5]. As shown in Figure 1, the process involves a rotating tool consisting of a pin and a shoulder. The pin is inserted between adjoining metal pieces and the shoulder remains at the top surface of the joint. The heat generated by the tool friction brings the metal to a plastic-like state and the pin mixes together the metal in the joint area resulting in a sound and homogenous joint. Unlike traditional welding processes (laser welding, GTAW, GMAW), the melting point